Die apparatus for making laminated panels



F. LYIJYNEN March 16, 1954 DIE APPARATUS FOR MAKING LAMINATED PANELS Original Filed April 3, 1946 3 Sheets-Sheet l` INVENTOR. 777e/ ggg/fem F. LYIJYNEN March 16, 1954 DIE APPARATUS FOR MAKING LAMINATED PANELS 5 Sheets-Sheet 2 Original Filed April 5, 1946 INVENTOR.

BY FTTaF/VEK March 16, 1954 F, LYUYNEN 2,672,176

DIE APPARATUS FOR MAKING LAMINATED PANELS Original Filed April 3, 1946 5 Sheets-Sheet 5 INVENTOR.

771e/ ggg/Maf?,

2 gew Patented Mar. 16, 1954 DIE APPARATUS FOR MAKING LAMINATED PANELS Fred Lyijynen, Detroit, Mich., assignor to Briggs Manufacturing Company, Detroit, Mich., a corporation of Michigan April 3, 1946, Serial No. and this application May 17, 1949, SerialNo. 93,660

Original application 659,405. Divided 6 Claims.

"This invention relatesy to ornamental panels and to the manufacture thereof, such panels being particularly, although not exclusively, adapted for use as inner trim panels of various types of vehicle. bodies, kespecially automobile bodies. One such panel, suitable for use in trimming the inside of an automobile door, may comprise two contrasting sections, i; e. an upper upholstered section and a lower kick-pad or kickpanel vsection which, although ofv ornamental or decorative character, is unupholstered.

This is a division of my co-pending application Ser. No.'659,405, led April 3, 1946, now U. S. Patent 2,573,466.

- An object of the invention is to provide an improved apparatus for making` an ornamental panel of the type having a. fabric covered foundation and in which the fabric or trim covering material is bonded to the foundation through the medium of a thermoplastic or thermosetting resinous substance.

A further object of the invention is to improve the manufacture of ornamental trim panels of the type having a found-ation,v a top layer or covering ofI fabric and an interposed layer of padding, an important feature of theinvention residing in the provision of improved means for stretching the fabric over the padding and foundation layers and the 4bonding of the layers while the fabric is in stretched condition.

Another object of the invention is to produce an improved apparatus for fabricating a trim panel or the like having an upholstered section and an adjoining kick-panel section,'provision being made for consolidating together and to the yfoundation adjacent edge portions of the cover sheets of the upholstered 4and kick-panel sections and thereafter stretching the fabric cover sheet before securing the opposite edge thereof to the foundation.

Still another object of the invention is to provide means for bonding and holding one edge of the fabric cover sheet tothe foundation while the opposite. edge'is drawn over the edge of the 'foundation to stretch .thexfabrid these latter ,K

edges being bondedtogetherwhile the fabric is in stretched or taut condition.

A further object of the invention is to impress ornamental grooves or depressions-in the coverinaterial to the foundation at thelocality of the grooves or deprcssionspsaid impressing operation being. performed `whilefthe fabric :covering .of the panelis in stretched orftaut condition.

Another 'objectfof'the invention isto attach a mg material of the trim panel and to bond this plurality of fastener devices to the undersidepf the foundation sheet during the fabricationcof the trim panel; the fasteners being united tothe foundation through the medium of resin impregnated materials which are consolidated Y.under heat and pressure with the foundation.

Other objects of this invention will appear'in the following description and appended claims, reference being had tothe accompanying drawings forming a part of this specication wherein like reference `characters designate corresponding parts in the several views.

Fig. 1 is a plan view of e, trim panel constructed in accordance with the invention, ythe metal molding or ornamental finish strips being omitted in this view.

Fig. 2 is a view similar to Fig. lvbut illustrating the metal moldings installed on the'trim panel.

Fig. 3 is a sectional elevation of a die or mold apparatus taken longitudinally through substantially the middle of the trim panel to be formed, the diesinthis View being `shownin open position.`

Figure 3A is an enlarged fragmentary'sectional View taken at the locality I4 in Fig. 3.

Fig. l is a View similar to Fig. 3 but illustrating the dies fully closed.

Fig. 5 is an enlarged detailed sectioniof the parts enclosed within the circle 5 in Fig. 3.

Fig. 6 is an enlarged fragmentary section ofthe fabric stretching mechanism Withy the dies in opened position.

Fig. '7 is a View similar to Fig. 6 but illustrating the dies in closed position.

Fig. 8 is an enlarged fragmentary section taken through the dies substantially along the lines 8 8 of Fig. 1 looking in the direction of the arrows.

Fig. 9 is an enlarged section taken through the dies substantially along lines 9-9 of Fig. 2 looking in the direction of the arrows.

Fig. 10 is an enlarged fragmentary section taken through the dies substantially alonglines lll-l0 of Fig.i2 looking in the vdirectionof the Before explaining in detail the present invention it is to be understood that the invention is not limited in its application to the details of Iconstruction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments andv of being practiced or carried out in various ways4 Also it is lto be understood that the phraseologyror terminology employed herein is for'the purpose of description and not of limitation.

fin Fig. 1 there .is illustrated, by lfwayf `of exempliiication of one embodiment of the invention, an ornamental panel A adapted to be mounted on the inside of an automobile door immediately below the window opening thereof for the purpose of covering the inner metal door panel and providing an ornamental finish for the inside of the door. The trim panel A is provided along the bottom thereof with an unupholstered socalled kick-pad or kick-panel section B which, in the present instance, is composed of consolidated laminations of sheet materials. The remainder of the trim panel above and laterally adjoining the kick-pad section B comprises an upholstered or fabric covered padded section C which, in the present instance, occupies the principal area of the panel and is formed on the fabric side thereof with ornamental grooves or depressions which may follow any desired design or pattern and in the localities of which the various laminations of the upholstered section of the panel are permanently bonded together. It will be understood that the design or pattern applied to the trim panel A and the configuration thereof are shown in Fig.

1 solely for the purposes of illustration since -f they may vary widely in accordance with the requirements as to ornamentation and design.

The trim panel comprises a relatively heavy foundation board I@ covered in one area thereof with a layer of padding or wadding Il which in turn is covered with a top sheet i2 of fabric or other equivalent trim material. The padding I I and fabric I2 form the upholstered section C of the trim panel. The adjoining area of the trim panel at the lower portion thereof, which is to be formed into the kick-panel section B, is provided with a covering layer I3 which is preferably in the form of cellulosic material. The covering material I3 of the kick-panel section B is provided along its upper edge with an extended portion overlapped at i4 by an extended portion of the fabric I2, and as hereinafter described these overlapping portions of the sheets I2 and 'I3 are embossed or compressed by die operation and at the same time bonded or consolidated together. The fabric I2 along its upper edge has an extended portion I2a which, as shown in Fig. '3,' extends beyond the upper edges of the foundation board IE) and padding layer II.

The foundation board l@ may be of any suitable composition, but is preferably formed of compressed fibrous stock so as to have the requisite strength, rigidity and stiffness. The foundation may be composed of one or a plurality of layers of paper or fibrous stock impregnated with a thermosetting resinous substance which are consolidated together under heat and pressure. The foundation may be treated or impregnated with a resinous substance and preformed to the shape illustrated, for example, in Fig. 3 with the resinous substance remaining after the preforming operation in an intermediate stage of reaction or polymerization. lt will be understood that the foundation board IQ may be fabricated or prepared in various ways, such for example, as in the manner disclosed in Cpending application Serial No. 614,978 filed September 7, 1945, now abandoned.

In the preforming operation between heated dies the kick-panel section B is preferably partially formed or shaped so as to approximate the final shape of the kick-panel B in the completed article. Preferably the foundation material is impregnated with a resin, such as a phenol-form aldehyde or melamine resin converted into varnish by the use of suitable solvents. This resinous material is preferably only partially cured or reacted during the preforming opera tion, thereby facilitating the consolidation of the padding and covering layers during the final operations illustrated in Figs. 3 and 4. It will be understood that the covering material I3 for the kick-panel section may comprise one or a plurality of sheets, preferably thin alpha-cellulose sheets in the form of white wood pulp paper or other fine grain cellulosic material. The covering material I3 is preferably given an ornamental nish such, for example, as a wood grain finish which may be applied thereto in any conventional manner.

After the preforming operation with respect to the foundation board I0, the latter is introduced into a press between upper and lower die members. The fabric material II and the covering material I3 are then superimposed in proper relation upon the foundation in the manner illustrated in Fig. 3 preparatory to the final operation of nally forming the panel to shape and consolidating together the various layers or laminations by the use of heat and pressure.

In the present instance the apparatus for completing the formation of the panel comprises a bed I5 upon which is secured a bottom die or platen I6. One edge of this platen at the upper face thereof adjacent the kick-panel is cut away to receive a die insert I1 rigidly secured to the platen I6. The upper surface of the die insert Il is shaped or contoured in accordance with the final shape of the kick-panel and adjoining portion of the foundation board ID. The opposite edge of the platen I6 at the upper face thereof is cut away transversely to provide a recess having a vertical wall I8 and a horizontal wall I9. Positioned within this recess in sliding contact with the Wall I8 is a draw or pressure pad 20 having a length corresponding to the width of the upper edge of the trim panel. This pad is recessed at 20a, to receive the upper end of a compression spring 2l, the lower end of this spring being seated within a recess 22 in the platen I6. Extended centrally through the coils of the spring 2| is a guide plunger 23 terminating at its lower end in a cylindrical head 23a. having a sliding fit within the cylindrical hole 24 in the platen. The plunger 23 has a threaded upper end screwed into a tapped hole in the pad 2.

The die or mold apparatus also includes an upper platen or punch member 25 recessed at one end to receive a stretching die insert 26 having a length corresponding to the length of the pad 20. This die insert projects somewhat below the adjacent lower face of the platen 25. Also anchored in fixed position within the recess in the platen 25 and lying adjacent the stretching die 26 is a creasing or embossing die insert 21, the lower edge of which terminates a predetermined distance above the lower edge of the die 26. Also xed within the recess in the lower face of the platen 25 is a die plate or die insert 28 shaped or contoured to conform to the final shape of the upper surface of the trim panel. Fixed Within a transverse groove or recess in the die insert 28 is a transverse groovng die insert 29. Also xed within grooves or recesses in the die 23 are a number of longitudinal grooving die inserts 3i), eachA bein-g formed integrally with a narrow creasing or embossing projection 30a, see Fig. 8. A transverse die or pressure pad 3l is slidingly fitted within a transverse opening 32 in the die 2a,f see..Fg. -f;3.l. This die made-3 I.:` .issbckdsiltz .1 compressionssnring .gutextending ...Antona :decessi-.- infthe platcn.25..,;. this.die padfbeing,.guideal..lernenl hea-dedplunele. 34..s1idab1e,- withn.;a .holelwithi-ri.

the-.platen,Yv Ther-...working ...Surface .of,...the. de2&.. D

oDpQsite.the.. kick=panel.;.section B ;of1 .the..trim panel. isi, curvedfgor,.contouredto .give. thesfllli shape.theretoanditerminates.in aprojecting por?, tion f.; 35. ...(Figs0 .3 and.. 5 l. .cooper-able... with.. the.. diei insert .-I 'I :.to.form an. irl-turned. .edge along.the.r 10 lowerfedgeof ,the.pane1,...

Whenthe. upperandlower .die .members `-asfy sumas-their.. relative positions eshown, in Fezg upondescent..of, theenppen ram onthe press, the., pressure (pad 3 I,- first rengagesrtheapanel. at.. the 15 locality-d4iottoverlap offfthe.fabric I2 and..top, laylaiv.t I3. .sof .f thewliickapanel: As. ,-the A ram .cone tinues 1to r.descend from .fthe .,position; sshown ..1 in a Fig. 3 toward the position shoWnfn:Fig...- 4 the., stretching-f diepengagesy 1theff-fabricr extension I 2a y,and clampsfthis extension .against the-upper.'` facenof-'f the .pressure lpad. 2 9. Continued..- descent ofitheram V.results y.in drawingdownward fab-1 ric fextension Za oven the .edgesefof y the :foundarf` tional and wadclins'15|I2.'v Since the fabric durs-- ing@ thisgoperation isz clamped along: 4the foppo-z siteaedgef-thereof bythe, pressure pad -3 I., the.: fab-r rie-wil1 :be stretched :longitudinallyl in the direc-fv tions ofi they fupperaedgenof.- theftriml f paneh. thusf. rendering the fabrie. tautz across@ the face'f'othef. o panelfffrom {lorca-html 4 .along-.fthe `upper-.f.edge Lof.- they. fkick-pane1 to :the: upper :edge of. .the trim :f pane1.f, The.coaction ofthstretchingvdiel-ZG with thewpressure-pad nfsvill. force.;.theslatterqdownf A wardlyi :toward the pcsitionfof, ,1Fi-g.= .7, 'andi-,afterl suiiiicientsstretching.; faction 1 has .taken vplace on the-fabric I2 :the creasing .ori embossing die 27. will engagefthehfabrie IZ-end wadding,= I I, com-v pressingthe samaandvforminga depressedgroove 3 6i along; fthe-,upper edge of.` the trinrpanel; Since` the @upper pla-tenvir and 'associated die insertsgas well: as- .thea :lowerf platen I Ii.y rare--` heated ato; f thel proper temperaturexthe:faction-vof the. dieninserti` 21. in: compressing i;theamaterials :tgformstha groove l36 1will result finr'consolidating. vthevfaln'ic.;` 45 I2.. waddingzr l I; and ,'Efoundation l I il: along rtliisf` groove'and creating,- a .permanenti 4bondrcfjzhese.l layersrzby acompleting. i the. curing; :or.polylnerizae` tioneof: thezresin: witnwhicmtlie .fo'undatiorrfand.A Wadding. ist impregnated or. treatedr:

After` fftlre; ',stretchirrgreof the; :.-fabriczfhas been; completedistha diei finsert29; will engage: theapanelf` andl compressxthe-maddingand `fabric: tri-form 1a transverse groove or channelel.- thereimrAetheesame time .the :ribszIlaaothendie:inserts llvvill 55 form narrow v.Vf-n'ticalr channels: ,fora :grooves '385 zine thefabric. and -waddirrgrand fthemressnrewpad r3 If: will pressr ,toge-ther the fkicklpanel top `sheet :I 331 fabric and Wadding to'rorms'a transverse 'chansne1-ff'39af- Irirlikemanner ornamental grooves 4e` may be :formed --in the `upperf-'face yof Vthe kicks panelelsee Figs. 2 and --10)^by `means-ofl suitable 'l groovingdie' inserts: .i

Before-th lfab1"ic -I2f irsapplied to the padding'.- II` preparatory `tol the die operationga suitable quantity' 'ofv resinous materialzin `the fo'rm'r'of lia: lacquer is preferably),applied as -by spraying or brushing to. the ,upper surface of Ltli'e. wadding. inthe. areas 36, Slgiland 353. Hence, when the... die. members .2 1.,; 29.,.,3Q .and .v3 I .engaeetthefmas teria1s undezi ipltessurezsaszshown' inrFigs'; 4,.; thezheatv from., tliesadie.' members as; `Well lasfrom: the; dieimembers-.I 6 and I 1. .Willeonsolidategtogethen; the various la'yers of the trim panel effecting a 75 permanent'..bond.ltherebetweensand.completing the@olymerizationofthresin.1

After .the. trim .panel hasbeenremoyed from;

the. die. :apparatusptheffree edge of ,the fabric along. thenpper. edge.orthepaneltmaybe turned under.. and .cemented any suitable. manner to the undersidekof. the-.foundation .I 0`, Tas. shown in row. ornamentallnoldings?, .maybe .anchored within;` the. .grooves ,.or. channels.` ..4012 in Vthe. kick. panel sectiom.

Ini,.tliepresentv embodiment.. I have .provided means..for, attaching fastenerdevices .44 to. .the underside. lof .the 1-kick-lpanel section B jnear the lower.. edge ,.tliereof, .these.. fasteners being. ine, tended. for. .-the.;purpose v of `attaclfling .the 1o wer edge, of .the .trim panel.. to.. the. inner. metal panel. As shown inFig., 5,.ea.ch., fastener 44; `..Whicl'ii isgof vtheconverging prong type,.has.. an. upperterminal.. head .44a confined or.-.frame. of.. the. door.

Withina pador. piece oipaper orbrous material 45. ,which .has been impregnated with. a partially polymerized resin. bling...tlie..trim .panel layers on the. platen I 6, 'are lodged. within recesses 46 in' the die. insert I 1, ias. shown .in Fig. 5. Asuitable' number. .of .fasteners 44.*mo11ntedswithin .padel-.45' fare, provided and spaced. apa-rt `transv ersel-:yat fthe. desired locations., Wlienxthe dies .are Vclosedlshe heatand pressure. of....the. cooperating dies. will Kforce the pads. 451mm ,thefoundation sheet. I l1 and` consolidate. them .together .to..,cr eate a permanenty bond v resultingjrom .the...nnalpolymerization of.. the.-V

resin. Thus,. .it1 will .be1 seen. that` this. operation will .g result. in permanently, .installing .the4 fas.-

tenersfM al-ongthe lower'edge ofrtheltrim panel.

I claimnl 1..In ;a press forrmakinga laminated panel. com-posed .offoundationand cover layers, upper andfloWer-g relatively `.movable .dies adapted to.V receive-.said layerse therebetween relatively. mow.

able, k.clamping ymembers carriedby. said. dies, an

uppergrippingmember carried .by the.. upper diey ata locality.. spaced .from said .clamping members,

a.lov/er..grippingmember carried by the lower.A die-and underlying.sthefiupper .gripping .member to cooperate therewithin.gripping the cover layer.-

during pressing.-y operation; .the lower gripping.; member, being.. yieldablaunder the. pressure of the iupper. vgripping .member-:during .the pressing operatiorrfa ldie:memben .carried .one .of said dies ...intermediate-.said ...clamping and gripping members .and ..adjacent..the :latter members and.

compress.. said layers at.. onef siderosaid gripping me2nb.ers.,.said gripping membersnwnen the press. ispfn being spaced aparty a distance .than

the. distance `lretvveen said .,die. member. and die.. portion thereby togrip a coverlayer during .closing. .of.. .the...press ...priore to.-,coo.peration of, said .die member and .dieportionto compress said layers,Y and .said- .c1a'mDinamemhers when. the. press 2. Ina 'press for making a laminated panel composed of foundation and cover layers, a pair of relatively movable dies adapted to receive said layers therebetween, relatively movable clamping members carried by said dies, a gripping member carried by the die confronting the cover layer and projecting from the surface of that die toward the other die, a yieldable gripping member carried by said other die and disposed to underlie the cover layer in opposition to the first gripping member and being yieldable under the pressure of the latter during a pressing operation, said gripping members being disposed at a locality spaced from said clamping members, a die member carried by one of said dies adjacent said gripping members and cooperable with a portion of the other die to compress said layers at one side of said gripping members, said gripping members when the press is open being spaced apart a less distance than the distance between said die member and die portion thereby to grip a cover layer during closing of the press prior to cooperation of said die member and die portion to compress said layers, said clamping members when the press is open being spaced apart a less distance than said gripping members thereby to clamp said layers during closing of the press prior to operation of the gripping members to grip said cover layer, and an embossing die portion carried by one of said dies and spaced from the other die when the press is open a distance greater than the spacing of said gripping members.

3. In a press for making a laminated panel composed of foundation and cover layers, a pair of relatively movable dies adapted to receive said layers therebetween with one die confronting the cover layer and the other die confronting the foundation layer, relatively movable clamping members carried by said dies, a gripping member carried by said one die and projecting therefrom toward the other die, a yieldable gripping member carried by said other die in opposition to said first gripping member and being yieldable under the pressure thereof during a pressing operation, means yieldingly resisting movement ofl the yieldable gripping member during said pressing operation, said gripping members being disposed at a locality spaced from said clamping members, a die member carried by one of said dies intermediate said clamping and gripping membersA L and cooperable with a portion of the other die to compress said layers, said gripping members when the press is open being spaced apart a less distance than the distance between said die member and die portion thereby to grip a cover y layer during closing of the press prior to cooperation of said die member and die portion to compress said layers, and said clamping members when the press is open being spaced apart a less distance than said gripping members thereby to clamp said layers during closing of the press` prior to operation of the gripping members to grip said cover layer. v

4. In a press for making avlavminated panel composed of foundation and cover layers, a pair of relatively movable dies adapted to receive said layers therebetween, opposed clamping members carried by said dies, one of said clamping members being yieldable under the pressure of the other during a pressing operation, means for resisting the yielding of said one clamping member, a gripping member carried by one-dieand projecting therefrom toward the other-diie, a'

yieldable gripping member carried by said `other die in opposition to saidrstgripping member and being yieldable underthe pressure thereof during a 'pressing operation, means for vresisting the yielding of Athe yieldable ygripping member, said gripping members being disposed at a locality spaced from said clamping members, a die member carried by one of said dies intermediate said gripping and clamping members and cooperable with a portion of the other die to compress said layers, said gripping members when the press is open being spaced apart a less distance than the distance between said die member and die portion thereby to grip a cover layer during closing of the press prior to cooperation of said die member and die portion to compress said layers, and said clamping members when the press is open being spaced apart a less distance than said gripping members thereby to clamp said layers during closing of the press prior to operation of the gripping members to grip said cover layer.

5. In a press for making a laminated panel composed of foundation and cover layers, a pair of relatively movable platens adapted to receive said layers therebetween, forming dies carried by said platens, relatively movable clamping portions carried` by the platens for clamping said layers together at one locality thereof, relatively movable stretching die members carried by the platens and spaced from said clamping members, said stretching die members being adjacent and outward of an edge of said dies intermediate said clamping portions and stretching die members, thereby to grip an edge of a cover layer extending beyond said dies, the stretching die member carried by one of said platens projecting from the surface thereof toward the stretching die member carried by the other platen, the latter stretching die member being yieldable under the pressure of the former stretching die member during a pressing operation, means resisting yielding of said latter stretching die member, a die portion carried by one of said dies alongside one of said stretching die members and cooperable with a portion of the other die to compress said layers, said stretching die members when the press is open being spaced apart a less distance than the distance between said die portions, thereby to grip said edge of the cover layer during closing of the press prior to cooperation of said die portions, and said clamping portions when the press is open being spaced apart a less distance than said stretching die members thereby to clamp said layers during closing of the press prior to cooperation of stretching die members.

6. In a press for making a laminated panel composed of foundation and cover layers, a pair of relatively movable platens adapted to receive said layers therebetween, forming dies carried byv said platens, relatively movable clamping portions carried by the platens for clamping said layers together at one locality thereof, relatively movable stretching die members carried by the platens and spaced from said clamping members, said stretching die members being adjacent and outward of an edge of said dies intermediate said clamping portions and stretching die members, thereby to grip an edge a cover layer eX- tending beyond said dies, the stretching (je iember carried by one of said platens projecting from 'the surface thereof toward the stretching die member earriedby the other platen, the latter stretching die `member being; yieldableunder the pressure ofthe former stretching die member during 'a pressing operationymeans resist- 9 ing yielding of said latter stretching die member, said stretching die members when the press is open being spaced apart a less distance than the distance between said dies, thereby to grip said edge of the cover layer during closing of the press prior to cooperation of said dies, and said clamping portions when the press is open being spaced apart a less distance than said stretching die members thereby to clamp said layers during closing of the press prior to cooperation of said stretching die members.

FRED LYIJYNEN.

References Cited in the 111e 0f this patent Number 5 Number 1 344,130

Name Date Wright Jan. 19, 1909 Jacoby Oct. 2, 1917 Stevens May 8, 1928 Leguillon et al Apr. 22, 1930 Straus Oct. 20, 1931 McGovern Dec. 29, 1931 Mitchell Dec. 20, 1938 Ball Jan. 10, 1939 Haberstump Aug. 15, 1939 Von Ende et a1. June 10, 1941 Koppln June 19, 1945 FOREIGN PATENTS Country Date Italy Oct. 24, 1936 

